WO2022093151A1

WO2022093151A1 - Map controlled thermostat assembly providing precise temperature control

Info

Publication number: WO2022093151A1
Application number: PCT/TR2021/050872
Authority: WO
Inventors: Murat RAZI
Original assignee: Kirpart Otomotiv Parcalari Sanayi Ve Ticaret Anonim Sirketi
Priority date: 2020-10-26
Filing date: 2021-08-28
Publication date: 2022-05-05
Also published as: TR202017105A1; DE112021005677T5

Abstract

The invention relates a map controlled thermostat assembly (10) providing precise temperature control. Specifically, the present invention relates to a map-controlled thermostat assembly (10) which provides precise temperature control according to real opening values of valve (20) element that are measured via a sensor. Thanks to the present invention, it is possible that ECU analyzes the real data of the valve (20) opening amount occurred versus the electrical energy applied to the piston (42).

Description

MAP CONTROLLED THERMOSTAT ASSEMBLY PROVIDING PRECISE TEMPERATURE CONTROL

Technical Field

The invention relates a map controlled thermostat assembly providing precise temperature control.

Specifically, the present invention relates to a map-controlled thermostat assembly which provides precise temperature control according to real opening values of valve element that are measured via a sensor.

Prior Art

It is well understood in the automobile industry that vehicles operates most efficiently when all fluids are circulating within the vehicle systems at their optimum temperatures. Thermostat assembly within engine cooling system provides proper cooling of the engine and its parts by determining the flow ratio between bypass circuitry and heat exchange circuitry. The change in the flow ratio between bypass circuitry and heat exchange circuity is possible with the change in the opening ratio between bypass inlet window and radiator inlet window or bypass outlet window and radiator outlet window. The change in the opening ratio is provided by the forward and backward motion of the valve structure guided by means of a thermo-actuator throughout thermostat interior space. The forward and backward motion of the valve structure is provided by the motion of the piston element of the thermoactuator.

In the conventional thermostat assemblies, the expandable material (such as wax ate.) within the heat sensitive reservoir causes the piston to move forward/backward, by expanding/shrinking (according to the actual temperature value of engine coolant) within the reservoir. Consequently, motion of the piston allows forward/backward motion of the valve structure guided by the thermoactuator. This type thermostat assemblies provide self-determined (independent) operation. However, the reaction rate of the conventional thermostat assembly towards temperature change is quite slow due to the time required for expansion/shrinkage of the expandable material.

For preventing this drawback of the conventional thermostat assemblies, electrically heated map- controlled thermostat assemblies have been used. In the electrically heated thermostat assemblies, externally-sourced heater inserted within piston of the thermo-actuator is used for providing the wax compound within the heat sensitive reservoir of the thermo-actuator to warm externally according to estimated engine conditions during a trip. Engine designers who know the engine working conditions well could estimate the cooling necessities of an engine during operation. Consequently, they define cooling maps according to the possible cases of engine. However, since engine necessities cannot be always predictable the cooling maps require feedback for verifying themselves. In the previous solutions, at least one temperature sensor has been placed at the inlet(s) or outlet(s) of the thermostat assembly for providing feedback to ECU (Engine Control Unit). However, temperature sensors cannot provide real data of valve opening to the ECU.

So, for precise temperature control of engine cooling system, there is a need for a thermostat assembly allowing the ECU to analyze the real data of the valve opening amount occurred versus the electrical energy applied to the piston.

The document US2019271995A1 (Thermostat Assembly with Position Sensor) mentions a thermostat designed only to notify the ECU if there is no opening or closing in the event of error. Unlike the present invention, it is not about map-controlled thermostat structure. In this US invention, electromagnetic field is obtained from a PCB (printed circuit board) placed where it is intended to be measured. This requires to wire and energize the PCB. Also, it uses another PCB to install a position reading sensor. This PCB uses microprocessor and sensor together. However, in the present invention, sensor communicates with the ECU directly via PWM (Pulse Width Modulation) and

do not

an external energy source to

. Present invention enables the thermostat to open and close with MAP control while the US invention becomes active just in the event of error.

The document US6659050B1 (Valve Assembly for Controlling Coolant Flow Exiting an Engine) mentions a thermostat assembly where distance control of valve is provided with motor. Also, unlike the present invention, it is not about map-controlled thermostat structure.

The document JPH10174359A (Position Sensor of Unit for Driving Direct-Acting Type Valve) mentions structure trying to measure distance with Hall effect sensors. Also, unlike the present invention, it is not about map-controlled thermostat structure.

As a result, there is a require for a map-controlled thermostat assembly which measures the real data of the valve position and send it to the ECU for providing precise temperature control according to real opening values of valve element. Objectives and Short Description of the Invention

The aim of the present invention is to present a map-controlled thermostat assembly which provides precise temperature control according to real opening values of valve element that are measured via a sensor.

A map-controlled thermostat assembly, comprising

- a frame,

- a valve structure,

- a thermo element including a reservoir with expandable material inside and a piston guided throughout mentioned reservoir via expandable material,

- a heater that is connected to mentioned piston and, in order to provide precise temperature control by allowing ECU to analyze the real data of the valve opening amount occurred versus the electrical energy applied to the piston; it comprises

- a magnet that is attached to mentioned valve structure or thermo element,

- a position sensor that is attached to the frame, measures position of mentioned magnet and sends the data to the ECU.

Preferred embodiments of the invention comprise a magnet nest formed on the valve structure for inserting said magnet therein.

Another embodiments of the invention comprise a magnet connector for attaching said magnet to the valve structure or thermo element.

Mentioned magnet connector includes a cavity or nest for the magnet to be inserted thereon/therein.

Preferred embodiments of the invention comprise sensor connector for attaching mentioned position sensor to the said frame.

Mentioned sensor connector includes a sensor nest for said position sensor to be inserted thereon/therein.

In the other embodiments of the invention, instead of usage the sensor connector, the position sensor is directly inserted within a cavity or nest formed on the frame.

Position sensor can be a magnetic field sensor.

Description of the Figures In Figure 1 , a sectional view of the present map-controlled thermostat assembly is shown.

In Figure 2, another sectional view of mentioned map-controlled thermostat assembly is given.

In Figure 3a, a perspective view of the present valve element is shown.

In Figure 3b, a sectional view of mentioned valve element is given.

In Figure 4a, a perspective view of present sensor connector is shown.

In Figure 4b, a sectional view of mentioned sensor connector is given.

In Figure 5, a perspective view of said map-controlled thermostat assembly is shown.

Reference Numbers

10. Thermostat assembly

10.1. Thermostat interior space

11. Frame

11.1. Piston seat

20. Valve

21. Magnet nest

30. Magnet

40. Thermo element

41. Reservoir

41.1. Expandable material

42. Piston

50. Heater connector

51. Heater

60. Sensor connector

61. Sensor nest

70. Position sensor

Detailed Description of the Invention

This invention relates to a map-controlled thermostat assembly (10) which provides precise temperature control according to real opening values of valve (20) element that are measured via a sensor. Thanks to the present invention, it is possible that ECU analyzes the real data of the valve opening amount (as a feedback) occurred versus the electrical energy applied to the piston (42). In the conventional map-controlled thermostat assemblies, at least one temperature sensor has been placed at the inlet(s) or outlet(s) of the thermostat assembly for providing feedback to ECU. However, temperature sensors cannot provide real data of valve opening to the ECU.

The present thermostat assembly (10) comprises a frame (11) including piston seat (11.1), a valve (20) structure including magnet nest (21), a thermo element (40) including a reservoir (41) with expandable material (41.1) and a piston (42) guided throughout mentioned reservoir (41) via expandable material (41.1), a heater (51) that is connected to mentioned piston (42), a magnet (30) that is attached to mentioned valve (20) structure or thermo element (40) a sensor attached to mentioned frame (11).

Mentioned sensor covers all structures that can measure position of valve (20) or thermo element (40). Position signals transmitted to the ECU by the position sensor (70) are used as feedback for ECU in terms of analyzing the real data of the valve opening amount occurred versus the electrical energy applied to the piston. Thus, the precise control of valve (20) opening amount and consequently precise control of the thermostat assembly (10) and engine cooling system becomes possible.

In the embodiment given in the figures, said sensor is a position sensor (70) such as magnetic field sensor etc. and it is attached to the frame (11) via a sensor connector (60). Mentioned position sensor (70) is located within a sensor nest (61) formed on/within the sensor connector (60). In the other embodiment of the invention, it is also possible that the sensor is directly placed on/attached to frame (11). Also, in some embodiments of the invention, sensor can be located within the cavity or nest formed on the frame (11).

In the embodiment given in the figures, mentioned magnet (30) is attached to the valve (20) by being inserted within a magnet nest (21) formed on the valve (20). However, in some embodiments of the invention, magnet (30) can be attached to the thermo element (40) instead of the valve (20). In the possible embodiments of the invention, it is possible that the magnet (30) is directly attached onto the valve (20) or thermo element (40) or it is attached indirectly via a connector to one of them. Mentioned connector may include a cavity or nest for the magnet (30) to be inserted therein. Mentioned heater (51) is connected to said piston (42) by means of a heater connector (50) attached to mentioned piston seat (11.1) of the frame (11). As known, according to the information taken from map-controller, ECU sends electrical signals to the heater (51) for controlling motion of the piston (42). Position sensor (70) attached to the frame (11) always measures the position of the magnet (30) which is attached to the valve (20) structure or thermo element (40). Since the magnet (30) is fixed to the valve (20) or thermo element (40), change in the position of the magnet (30) is directly gives us the change occurred in the position of the valve (20) or thermo element (40) throughout the thermostat interior space (10.1). The obtained signals are transmitted to the ECU for calculating linear position change of the valve (20) or thermo element (40) and analyzing the real data of the valve (20) opening amount occurred versus the electrical energy applied to the piston (42).

Briefly, present invention emerges as a solution that supports or even eliminates the empirical calculation in the traditional method (estimating the position of the valve according to the temperature of the engine coolant) by allowing the actual (real) position of the valve (20) to be measured. This invention is not restricted with the above mentioned embodiments. In the other embodiments of the invention, vice versa, it is also possible that magnet (30) is attached to the frame (11) while the position sensor (70) is attached to the valve (20) structure or thermo element (40).

Claims

7 CLAIMS

1. A map-controlled thermostat assembly (10), comprising a frame (11), a valve (20) structure, a thermo element (40) including a reservoir (41) with expandable material (41.1) and a piston (42) guided throughout mentioned reservoir (41) via expandable material (41.1), a heater (51) that is connected to mentioned piston (42) and, characterized by; in order to provide precise temperature control by allowing ECU to analyze the real data of the valve (20) opening amount occurred versus the electrical energy applied to the piston (42); comprising a magnet (30) that is attached to mentioned valve (20) structure or thermo element (40), a position sensor (70) that is attached to the frame (11), measures position of mentioned magnet (30) and sends the data to the ECU.

2. A map-controlled thermostat assembly (10) according to Claim 1 and, characterized by; comprising a magnet nest (21) formed on the valve (20) structure for inserting said magnet (30) therein.

3. A map-controlled thermostat assembly (10) according to Claim 1 and, characterized by; comprising a magnet connector for attaching said magnet (30) to the valve (20) structure or thermo element (40).

4. A map-controlled thermostat assembly (10) according to Claim 3 and, characterized in that; mentioned magnet connector includes a cavity or nest for the magnet (30) to be inserted therein.

5. A map-controlled thermostat assembly (10) according to one of the preceding claims and, characterized by; comprising a sensor connector (60) for attaching mentioned position sensor (70) to the said frame (11).

6. A map-controlled thermostat assembly (10) according to Claim 5 and, characterized in that; mentioned sensor connector (60) includes a sensor nest (61) for said position sensor (70) to be inserted therein. 8

7. A map-controlled thermostat assembly (10) according to one of the Claims 1-4 and, characterized in that the frame (11) includes a cavity or nest for the position sensor (70) to be inserted therein.

8. A map-controlled thermostat assembly (10) according to one of the preceding Claims and, characterized in that the position sensor (70) is a magnetic field sensor.